Delica Canada | Mitsubishi Van Club

Okay, I bought this Chinese solenoid for $10, and it seems pretty solid. The only bad part is the bolts are imperial, and I just hate having two sets of spanners to work on a used car. I don't want to change the lugs on my wires to accommodate the larger bolts.

I realized that if I file the threads off the bolts, I can recut the studs with metric threads. Here we go:
Note that I bent the mounting bracket out of the way first, to make room for filing and cutting threads. Next, I cut threads in the stud with a 6mm x 1.0 die:
Fits the original nuts:
I decided the bolts didn't need to be so long, so ground them shorter:
The finished mod, with the mounting bracket bent flat:
I made an adapter to go from the coil stud to a blade, to plug in the actuator wire:
The Chinese solenoid, transplanted to the Delica:
So that's how you replace a failed glow plug relay solenoid for $10, without modifying the Delica. If you happen to get a $350 replacement solenoid for Christmas, you can swap it in.

That looks like 3/8 UNC to me, which has a 1/2" hex nut? I've always found 13mm to be pretty good on 12.5mm flats Nice work though :D

Actually, you should have filed the nuts down to 12mm to match all the other nuts on the delica!

If it fails WARN makes a same style but 100% duty cycle version for winches.... they are little more money but worth every penny...

Yeah, the main issue is being able to slip the crimp connectors onto the bolts, and tighten them with a metric spanner. I figure the 1/2" nut holding the bolt in place isn't likely to go anywhere.

Well just my two cents.....all this seems like an awful lot of work all for the sake to not have any imperial wrenchs in your toolbox. cant hurt to have a set of imperial 3/8 sockets and wrenches....you would sure be cursing your arse off camping/offroading in the woods knowing the only
thing stopping you or a buddy from making it out is an imperial wrench or socket. Metric fits close but close doesnt cut it with seized nuts or bolts

Very cool mod! I love the attention to detail.

Carrying a small adjustable wrench could also be a solution to the Metric / Imperial dilema.

I carry a set of these wrenches in my toolbox so I con't have to carry too many wrenches. They work great.

http://www.canadiantire.ca/en/pdp/maste ... TkuBiFVhBc

The Mitsubishi and this chineese replica seems to be 3 pins while the Warn are 4..How do you fits it with the Delica wiring ? Any part number for this Warn Solenoid ?

Thanks

Lapprentis